May 2006

Heat Transfer

Optimizing O2 levels in fired heaters

Here's the procedure this plant used to reduce fuel consumption and emissions

Patel, S., Petro-Canada

Combustion efficiency of fired heaters reduces considerably if the air supply is significantly higher or lower than the theoretically required air. Typically, in the hydrocarbon process industry, maintaining correct excess O2 level in fired heaters merits little attention and is poorly understood compared with other efficiency improvement ideas. By targeting correct excess O2 level, one company had significant success in its effort to reduce fuel consumption and associated greenhouse gas (GHG) emissions at one of its hydrogen plants. In this plant alone, the company saved 117 MMscf of refinery fuel gas annually with a value of CDN $460,000 at $6/GJ natural gas price. And CO2 emissions were

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